内孔热喷涂技术的研究现状与展望
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摘要
在机械制造、石油化工、航空航天和钢铁冶金等工业领域,存在着很多关键而重要的内孔类零部件,例如:发动机气缸体、燃气轮机壳体、液压机构仝缸和各种泵送管路等。内孔类零部件常服役于极端温度、腐蚀介质、高比负荷等苛刻工况下,易于发生严重的磨损、腐蚀失效。内孔热喷涂技术是在零件内壁制备涂层的重要方法,可以对内孔类零部件进行强化改性或对报废零件实施再制造。文中首先从技术原理、作业方式、发展历程和工业应用等方面系统介绍了内孔等离子粉末喷涂、内孔等离子丝材喷涂、内孔超音速火焰喷涂和内孔电弧喷涂4种最典型的内孔热喷涂技术。在此基础上,全面对比了各项技术的优、缺点,包括工艺成本、选材范围和涂层性能等。随后分别从涂层结合强度提升、涂层孔隙和厚度控制、涂层残余应力调控等方面指出了内孔喷涂工艺相比于普通外缘喷涂的特殊性,并总结了相应的技术难点,包括喷涂距离受限、局部热量累积、粉尘聚集和污染等等。最后指出,进一步揭示涂层微观成形机理、提升涂层与基体结合强度、发展多种表面技术复合工艺等是内孔热喷涂技术今后的重点研究方向。
There are numerous critical inner bore parts in the industrial fields of mechanical manufacture, petrochemical,aeronautics and astronautics, and ferrous metallurgy, such as cylinder barrel of engine, gas turbine housing, cylinder in hydraulic mechanism and different types of pumping lines. These parts are always operating at harsh environment, like extreme temperature, corrosion medium, high load, etc., which easily causes severe failure of wear and corrosion. Internal thermal-spray technique is an important process for depositing coatings on inner surface of parts, which can strengthen the parts or remanufacture those scrapped components. This paper first introduces four typical internal thermal-spray techniques,including internal diameter-plasma spraying, plasma transferred wire arc, internal diameter-high velocity oxygen/air flame and internal diameter-wire arc spraying, from the aspects of technical principle, operation mode, development process and industrial application. On this basis, pros and cons of each technique are compared comprehensively, including process cost,materials selection and coatings performance. Then, features of those techniques are proposed from the perspective of interface bonding, control of porosity and thickness of the coating, and regulation of residual stress. The corresponding technical difficulties are summarized containing local accumulation of thermal and dust, and stress cracking of the coating. Finally,prospects for the development of the technology are discussed consisting of micro-forming mechanism of coatings, increasing the bonding strength between the coating and the substrate, and developing various composite surface engineering techniques.
There are numerous critical inner bore parts in the industrial fields of mechanical manufacture, petrochemical,aeronautics and astronautics, and ferrous metallurgy, such as cylinder barrel of engine, gas turbine housing, cylinder in hydraulic mechanism and different types of pumping lines. These parts are always operating at harsh environment, like extreme temperature, corrosion medium, high load, etc., which easily causes severe failure of wear and corrosion. Internal thermal-spray technique is an important process for depositing coatings on inner surface of parts, which can strengthen the parts or remanufacture those scrapped components. This paper first introduces four typical internal thermal-spray techniques,including internal diameter-plasma spraying, plasma transferred wire arc, internal diameter-high velocity oxygen/air flame and internal diameter-wire arc spraying, from the aspects of technical principle, operation mode, development process and industrial application. On this basis, pros and cons of each technique are compared comprehensively, including process cost,materials selection and coatings performance. Then, features of those techniques are proposed from the perspective of interface bonding, control of porosity and thickness of the coating, and regulation of residual stress. The corresponding technical difficulties are summarized containing local accumulation of thermal and dust, and stress cracking of the coating. Finally,prospects for the development of the technology are discussed consisting of micro-forming mechanism of coatings, increasing the bonding strength between the coating and the substrate, and developing various composite surface engineering techniques.
引文
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